Water heater and system for insulating same

A water heater comprising:

• a water tank;
• an outer shell surrounding said water tank;
• a foam distribution device disposed between said water tank and said outer shell, said device extending only partially around a perimeter of said water tank;
• and
• an insulation member disposed between said water tank and said outer shell and positioned below said foam distribution device such that a gap or a space exists between a bottom external surface of said foam distribution device and a top surface of said insulation member, wherein the gap is sized for receiving foam insulation to thermally insulate an area defined between the bottom external surface of said foam distribution device and the top surface of said insulation member.

A method of assembling a water heater comprising the steps of:

• positioning an insulation member at a bottom end portion of a water tank;
• mounting a foam distribution device to the water tank such that it partially extends around a perimeter of the water tank and terminates at an elevation above the insulation member;
• delivering foam insulation into a body portion of the foam distribution device, through an outlet opening defined in the body portion of the foam distribution device extending along a portion of a side of the body portion and defined at an elevation between a closed too side portion defined along the side of the body portion and a closed lower side portion that is also defined along the side of the body portion, and into a gap defined between the water tank and an outer shell of the water heater;
• and
• attaching a cover to the outer shell of the water heater, thereby substantially enclosing the foam insulation.

A method of assembling a water heater including a water tank positioned above a combustion chamber, said method comprising the steps of:

• positioning an insulation member about the combustion chamber;
• mounting a foam distribution device to the water tank such that it only partially extends around a perimeter of the water tank and terminates at an elevation above the insulation member such that a gap is defined between a closed lower end of the foam distribution device and a top surface of the insulation member that faces the closed lower end of the foam distribution device;
• delivering foam insulation into a body portion of the foam distribution device, through an outlet opening defined in the body portion of the foam distribution device and into the gap defined between the closed lower end of the foam distribution device and the top surface of the insulation member;
• and
• attaching a cover to an outer shell of the water heater, thereby substantially enclosing the foam insulation.

A water heater comprising:

• a water tank;
• an outer shell surrounding said water tank;
• a foam distribution device disposed between said water tank and said outer shell, said device extending only partially around a perimeter of said water tank, said foam distribution device including:
• a body portion having a top end, a bottom end opposite the top end and two sides extending between the top end and the bottom end, said body portion at least partially defining a flow passage for foam insulation;
• opposed flap portions extending from the top end of said body portion;
• means for attaching at least one of said flap portions to the water tank;
• and
• a trough defined at the bottom end of the body portion for collecting foam insulation, said trough being defined by a closed bottom side at the bottom end of the body portion and closed lower sides, each closed lower side extending from the closed bottom side and along at least a portion of a respective side of the body portion;
• and
• an insulation member disposed between said water tank and said outer shell, said insulation member positioned below said foam distribution device such that a gap or a space exists between a bottom surface of said foam distribution device and a top surface of said insulation member, wherein the gap is sized to receive foam insulation for thermally insulating an area defined between the bottom surface of said foam distribution device and the too surface of said insulation member.